U.S. patent application number 12/569502 was filed with the patent office on 2010-04-08 for reduced size multi-pin female receptacle connector.
This patent application is currently assigned to Apple Inc.. Invention is credited to S. Brian Lynch, Jason Sloey, Stephen Paul Zadesky.
Application Number | 20100087098 12/569502 |
Document ID | / |
Family ID | 41263708 |
Filed Date | 2010-04-08 |
United States Patent
Application |
20100087098 |
Kind Code |
A1 |
Sloey; Jason ; et
al. |
April 8, 2010 |
Reduced Size Multi-Pin Female Receptacle Connector
Abstract
Receptacle connectors and male plug connectors having a reduced
size in at least one direction can be provided. One example reduces
height by not including a center contact tab or tongue, but instead
places contacts on an insulator that is adjacent to a bottom
portion of the receptacle. Another example may reduce width by
reducing contact pitch, and may use a particular shape of contact
to achieve god signal quality. Receptacle connectors and male plug
connectors can also provide support for one or more new high-speed
communication standards, such as USB 3.0 and DisplayPort. Methods
can provide one or more standardized connector components to speed
connector design and manufacture of new electronic devices such as
media players, thus reducing their time to market.
Inventors: |
Sloey; Jason; (San Jose,
CA) ; Lynch; S. Brian; (Portola Valley, CA) ;
Zadesky; Stephen Paul; (Portola Valley, CA) |
Correspondence
Address: |
TOWNSEND AND TOWNSEND AND CREW, LLP
TWO EMBARCADERO CENTER, 8TH FLOOR
SAN FRANCISCO
CA
94111-3834
US
|
Assignee: |
Apple Inc.
Cupertino
CA
|
Family ID: |
41263708 |
Appl. No.: |
12/569502 |
Filed: |
September 29, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61101151 |
Sep 30, 2008 |
|
|
|
Current U.S.
Class: |
439/660 ;
29/747 |
Current CPC
Class: |
H01R 24/62 20130101;
Y10T 29/53209 20150115; H01R 2107/00 20130101; H01R 13/405
20130101; H01R 13/6581 20130101; H01R 13/6471 20130101; H01R
13/4538 20130101; H01R 13/6474 20130101; H01R 43/24 20130101; H01R
13/502 20130101 |
Class at
Publication: |
439/660 ;
29/747 |
International
Class: |
H01R 24/00 20060101
H01R024/00; H01R 43/20 20060101 H01R043/20 |
Claims
1. A receptacle connector for connecting to a corresponding male
plug connector, the receptacle connector comprising: a shell having
a top, a bottom, a first side, a second side opposite the first
side, and an opening at a front of the receptacle connector; an
insulator core having a bottom surface that is adjacent with an
inner surface of the bottom of the shell; a plurality of locations
for contacts, the contact locations spaced apart in a single row
and located on a top surface of the insulator core; and a cavity
including: a first region between the top surface of the insulator
core and the top of the shell; and a second region between sides of
the insulator core and the sides of the shell, wherein the cavity
of the receptacle connector is configured to receive the male plug
connector.
2. The receptacle connector of claim 1, wherein the insulator core
includes: a first chamfer at a first end of a front surface of the
insulator core; and a second chamfer at a second end of the front
surface, the second end opposite the first end, wherein the
chamfers provide a lateral alignment of the male plug connector
with the receptacle connector.
3. The receptacle connector of claim 1, further comprising: a
plurality of contacts located in at least a portion of the
plurality of contact locations.
4. The receptacle connector of claim 3, wherein the plurality of
contacts include: a plurality of signal contacts; and a plurality
of ground contacts, each ground contact separated from another
ground contact by two signal contacts.
5. The receptacle connector of claim 4, wherein the number of
ground contacts is nine.
6. The receptacle connector of claim 4, wherein the signal contacts
include: a first set of signal contacts for carrying USB 3.0
signals; and a second set of signal contacts for carrying
DisplayPort signals.
7. The receptacle connector of claim 3, wherein each contact has a
first section located within the insulator core, wherein the first
section of at least one contact has sides that are substantially
parallel to each other except for one or more recesses, and wherein
a side of the at least one contact faces the other contacts.
8. The receptacle connector of claim 7, wherein the surface of a
recess is curved.
9. The receptacle connector of claim 7, wherein the first section
of a contact includes a front end that bends downward toward the
bottom surface of the insulator core, the front end including a
front edge at a top of the front end, wherein the front edge is
embedded in the insulator core at a point below the top surface of
the insulator core.
10. The receptacle connector of claim 7, wherein the contacts have
a pitch of 0.4 mm.
11. A receptacle connector for connecting to a corresponding male
plug connector, the receptacle connector comprising: an insulator
core; a plurality of contact locations spaced apart in a single row
and located on a first surface of the insulator core; and a
plurality of contacts located in at least a portion of the
plurality of contact locations, wherein each contact has a first
section located within the insulator core, and wherein the first
section of at least one contact has sides that are substantially
parallel to each other except for one or more recesses, and wherein
a side of the at least one contact faces the other contacts.
12. The receptacle connector of claim 11, wherein the first section
of all of the contacts have sides that are substantially parallel
to each other except for one or more recesses, and wherein a side
of the at least one contact faces the other contacts.
13. The receptacle connector of claim 11, wherein the first section
of at least one contact has one recess on each side.
14. The receptacle connector of claim 11, further comprising: a
shell having a top, a bottom, a first side, a second side opposite
the first side, and an opening at a front of the receptacle
connector, wherein the insulator core has a bottom surface that is
opposite the first surface of the insulator core and that is
adjacent with an inner surface of the bottom of the shell; and a
cavity including: a first region between the top surface of the
insulator core and the top of the shell; and a second region
between sides of the insulator core and the sides of the shell,
wherein the cavity of the receptacle connector is configured to
receive the male plug connector.
15. The receptacle connector of claim 11, wherein the surfaces of
the recesses are curved.
16. The receptacle connector of claim 11, wherein a slope at any
point on the surface of each recess is at an angle of less than 45
degrees with respect to the plane of the side surface that the
recess is on.
17. The receptacle connector of claim 11, wherein the first section
of a contact includes a front end that bends downward toward the
bottom surface of the insulator core, the front end including a
front edge at a top of the front end, wherein the front edge is
embedded in the insulator core at a point below the top surface of
the insulator core.
18. A receptacle connector for connecting to a corresponding male
plug connector, the receptacle connector comprising: an insulator
core; and a plurality of contact locations spaced apart in a single
row and located on a first surface of the insulator core, wherein
the contact locations include a first portion of contact locations
designated for ground and a second portion of contact locations
designated for carrying signals, and wherein each of the pairs of
contact locations of the second portion separate respective contact
locations of the first portion
19. The receptacle connector of claim 18, wherein the signals
include data or power signals, or both.
20. The receptacle connector of claim 18, wherein the first portion
of contact locations include a first contact location at a first
end of the single row of contact locations and include every third
contact location from the first contact location.
21. The receptacle connector of claim 18, further comprising: a
plurality of contacts at the plurality of contact locations, the
plurality of contacts including ground contacts at the first
portion of contact locations and signal contacts at the second
portion of contact locations.
22. The receptacle connector of claim 21, wherein the signals
include USB 3.0 signals and DisplayPort signals.
23. The receptacle connector of claim 22, wherein a level of
crosstalk between signals on the signal contacts is less than
3%.
24. The receptacle connector of claim 22, wherein an impedance of
contacts for carrying USB 3.0 signals is 90 Ohms plus or minus 10%,
and wherein an impedance of contacts for carrying DisplayPort
signals is 100 Ohms plus or minus 10%.
25. A method of manufacturing a plurality of receptacle connectors
for a variety of types of media players, the method comprising:
providing a plurality of substantially identical insulating cores,
each insulating core including a plurality of contacts; and
providing a plurality of types of shells, each shell configured to
attach to any one of the plurality of insulating cores, each type
of shell configured to be used in the assembly of a different type
of media player; for each of the plurality of substantially
identical insulating cores: selecting one of the plurality of types
of shells; and attaching the selected shell to the respective
insulating core.
26. The method of claim 25, wherein providing each of the plurality
of substantially identical insulating cores includes: providing a
plurality of contacts; and insert molding an insulating material
around the plurality of contacts.
27. The method of claim 25, wherein attaching the selected shell to
the respective insulating core includes placing the insulating core
on an inside bottom surface of the selected shell.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from and is a
nonprovisional application of U.S. provisional application No.
61/101,151, filed Sep. 30, 2008, titled "REDUCED SIZE MULTI-PIN
CONNECTOR," which is incorporated by reference. This application is
also related to commonly owned and concurrently filed U.S. Patent
Application entitled "REDUCED SIZE MULTI-PIN MALE PLUG CONNECTOR "
by Sloey et al. (attorney docket number 20750P-008710US), the
disclosure of which is incorporated by reference in its
entirety.
BACKGROUND
[0002] Electronic devices such as media players and related devices
have become ubiquitous over the past several years. As they have
proliferated, the types and styles of electronic devices have
diversified. During this time, a theme has been that consumers want
more functionality packed into an ever-decreasing form factor.
[0003] At the same time, many new high-speed communication
standards have been developed. Examples of these new standards
include the new high-speed USB3, DisplayPort, and others. Although
it is desirable to have an electronic device such as a media player
be able to use these new high-speed communication standards, these
new standards are often tough to meet. Meanwhile, it is also
desirable that electronic devices be able to also communicate using
conventional signaling such as analog audio and video.
[0004] Also, as the styles and types of electronic devices such as
media players are expected to continue to multiply, it is desirable
that these new styles and types be able to be introduced quickly to
the marketplace.
SUMMARY
[0005] Accordingly, various embodiments of the present invention
can provide male plug connectors and female receptacle connectors
that may have a reduced size in at least one direction. Some
embodiments of the present invention can provide support for one or
more new high-speed communication standards. Further embodiments of
the present invention can provide one or more standardized
connector components to speed connector design and manufacture of
new electronic devices such as media players, thus reducing their
time to market. These electronic devices may range from smaller
hand-held devices, which may include portable media players, to
larger devices, such as laptop or desktop computers.
[0006] An embodiment of the present invention may provide a
receptacle connector having a reduced height. The receptacle
connector can include a shell, an insulator core, and a cavity
configured to receive the male plug connector. The shell can have a
top, a bottom, a first side, a second side opposite the first side,
and an opening at a front of the receptacle connector. The
insulator core can have a bottom surface that is adjacent with an
inner surface of the bottom of the shell. A plurality of locations
can be spaced apart in a single row and located on a top surface of
the insulator core. The cavity can include a first region between
the top surface of the insulator core and the top of the shell and
a second region between sides of the insulator core and the sides
of the shell.
[0007] Another embodiment of the present invention may provide a
receptacle connector having a reduced width. The width may be
reduced by reducing a width of contacts or spacing between
contacts, or both. The contacts may have a first section located
within an insulator core. The first section of at least one contact
can have sides that are substantially parallel to each other except
for one or more recesses. High-speed data communications may be
achieved with such a contact, with or without a reduced width of
the connector.
[0008] Another embodiment of the present invention may provide a
receptacle connector that can include an insulator core and a
plurality of contact locations spaced apart in a single row and
located on a first surface of the insulator core. The contact
locations can include a first portion of contact locations
designated for ground and a second portion of contact locations
designated for carrying signals. The contact locations of the first
portion can be separated from each other by two contact locations
of the second portion.
[0009] Another embodiment of the present invention may provide a
method of manufacturing a plurality of receptacle connectors for a
variety of types of media players. A plurality of substantially
identical insulating cores, each insulating core including a
plurality of contacts, can be provided. A plurality of types of
shells can also be provided. Each shell can be configured to attach
to any one of the plurality of insulating cores, and each type of
shell can be configured to be used in the assembly of a different
type of media player. For each of the plurality of substantially
identical insulating cores, one of the plurality of types of shells
can be selected, and the selected shell can be attached to the
respective insulating core.
[0010] Various embodiments of the present invention may incorporate
one or more of these and the other features described herein. A
better understanding of the nature and advantages of the present
invention may be gained by reference to the following detailed
description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a simplified perspective view of a representative
media player and male plug connector (neither of which are drawn to
scale) that may be improved by the incorporation of embodiments of
the present invention.
[0012] FIGS. 2A-2C are simplified front and cross-sectional side
views of a connector arrangement including a male plug connector
and a receptacle connector (neither of which are drawn to scale)
that may be improved by the incorporation of embodiments of the
present invention.
[0013] FIG. 3A illustrates a perspective view of a receptacle
connector that can carry multiple high-speed data signals according
to embodiments of the present invention.
[0014] FIG. 3B is a block diagram illustrating the transmission of
DisplayPort and USB 3.0 signals between receptacle connector and a
male plug connector.
[0015] FIG. 4 shows a contact designation chart illustrating types
of signals designated to be carried by contacts at various contact
locations according to embodiments of the present invention.
[0016] FIGS. 5A-5C show plots illustrating simulated performance
characteristics of a connector having a contact designation
according to embodiments of the present invention.
[0017] FIG. 6A shows an example of the types and specific number of
signals that may be carried on connectors according to embodiments
of the present invention.
[0018] FIGS. 6B-6F show examples of contact designations (pinouts)
for receptacle connectors and corresponding male plug connectors
according to embodiments of the present invention.
[0019] FIG. 6G illustrates a mating sequence and wiping distance of
pinouts according to embodiments of the present invention.
[0020] FIG. 7 shows a top view of a conventional contact used in a
receptacle connector.
[0021] FIG. 8A shows a top view of a contact that can be used in a
reduced-width connector while maintaining signal quality at high
frequencies according to embodiments of the present invention.
[0022] FIG. 8B shows a side view of contact that can provide
reduced wear as a result from mating according to embodiments of
the present invention.
[0023] FIG. 9 is a flowchart illustrating a method 900 for making
receptacle connector according to embodiments of the present
invention.
[0024] FIG. 10 illustrates perspective and front views of a
receptacle connector 1000 that has a reduced height according to
embodiments of the present invention.
[0025] FIG. 11 illustrates a male plug connector 1100 with a
reduced height according to embodiments of the present
invention.
[0026] FIG. 12 illustrates keying aspects of connectors to prevent
accidental inverted insertion of a male plug connector 1250 into a
receptacle connector 1200 according to embodiments of the present
invention.
[0027] FIG. 13 illustrates mechanisms for aligning a male plug
connector with a receptacle connector according to an embodiment of
the present invention.
[0028] FIGS. 14A-14C illustrate cross-sectional side views of
different stages during an insertion of a male plug connector into
a receptacle connector according to embodiments of the present
invention.
[0029] FIG. 15 illustrates a male plug connector 1500 with a
reduced height and a moveable door 1 according to embodiments of
the present invention.
DETAILED DESCRIPTION
[0030] Certain embodiments can provide connectors having a reduced
size in at least one dimension, which can allow electronic devices
using such connectors to be reduced in size. Some embodiments can
provide connectors that can support communication using one or more
of high-speed interface standards, where such standards can include
a restriction on an amount of cross-talk between signals and
impedance of contacts. Embodiments can also provide one or more
components of the connector that are standardized or generic such
that they can be used in different styles and types of electronic
devices (such as media players).
[0031] FIG. 1 is a simplified perspective view of a representative
media player 100 and male plug connector 120 (neither of which are
drawn to scale) that may be improved by the incorporation of
embodiments of the present invention. Media player 100 may have an
LCD screen 114 for viewing and a click wheel 112 for control. Other
embodiments may include a touch screen, keyboard, or other
interface components (not shown).
[0032] Media player 100 includes a receptacle connector 110 into
which an insert 128 of a male plug connector 120 can be inserted.
In this example, receptacle connector 110 is shown as having an
insert 128 that is square, though in other embodiments it may be
rounded or have other shapes. Insert 128 may include connector tabs
122 on one or more sides (tabs may also be on a top or bottom) that
fit into slots on receptacle connector 110 to prevent accidental
removal of insert 128 from receptacle connector 110. To remove
insert 128, connector release buttons 124 may be pushed and insert
128 withdrawn from receptacle connector 110.
[0033] Typically, when a cable 126 is used, cable 126 connects
media payer 110 to a computer or other device or accessory (not
shown). In this way, the computer can update media and other
information on media player 100, retrieve information, provide
control, charge a battery on media player 100, or provide or
perform other functions. Media player 100 may also connect to an
accessory through a docking station (e.g. having a male plug
connector), and may be partially supported in the docking station
with an appropriately sized insert that allows the docking station
to accommodate different sized media players Such a connection
allows the accessory to pass and receive information to media
player 100, charge a battery on media player 100, and perform or
provide other functions.
[0034] FIGS. 2A-2C are simplified front and cross-sectional side
views of a connector arrangement including a male plug connector
200 and a receptacle connector 250 (neither of which are drawn to
scale) that may be improved by the incorporation of embodiments of
the present invention. These connectors are typically used to
convey data and power to/from an electronic device, such as media
player 100.
[0035] FIG. 2A shows a front view of a male plug connector 200
having a shell 205, an insulator 210, and contact pins 215. The
male plug connector 200 is designed to have its shell 205 fit
inside a corresponding receptacle connector. An example of such a
connector is a universal serial bus (USB) connector.
[0036] FIG. 2B shows a front view of a receptacle connector 250
having a shell 255, an insulator tongue 260, and contact pins 265.
Insulator 260 is a tongue that projects into a central region of a
cavity 270, which surrounds the tongue. An upper section 270a of
the cavity lies between insulator 260 and a top of shell 255, and a
lower section 270b of the cavity lies between insulator 260 and a
bottom of shell 255, thereby defining tongue 260. Shell 255 is
larger than shell 205 so that male plug connector 200 can fit
inside female receptacle connector 250.
[0037] FIG. 2C shows a cross-sectional side view of a connector
arrangement created when male plug connector 200 is inserted into
female receptacle connector 250. Shell 205 and insulator 210 are
connected to a base 230, and shell 255 and insulator tongue 260 are
connected to a base 280. Bases 230 and 280 may be grabbed by a
user's hand during insertion.
[0038] As shown, shell 205 fits inside shell 255. Specifically,
shell 205 fits between a top of tongue 260 and shell 255 in cavity
region 270a. Shell 205 also fits between a bottom of tongue 260 and
shell 255 in cavity region 270b. Although, a space is shown between
shells 205 and 250, typically the shells would touch.
[0039] Such connectors often carry only one type of data signal,
e.g. USB signals. Thus, if one wanted to provide multiple types of
data signals to a media player using such connectors, multiple
connectors would be required. Alternatively, embodiments of the
present invention have a connector that can provide multiple
interfaces. However, providing multiple high-speed interfaces with
tight tolerances on a single connector can be difficult.
Accordingly, embodiments of the present invention can provide
receptacle connectors and corresponding male plug connectors that
provide high-speed interfaces while maintaining the standards
required by the interfaces.
[0040] Additionally, as the size of media player 100 decreases, the
size of receptacle connector 110 becomes increasingly important.
This is true for the size of the opening, that is, the receptacle
connector's height and width, as well as its depth. A smaller
opening allows media player 100 to be made thinner and narrower,
while a shallower depth means that receptacle connector 110
consumes less of the usable area inside media player 100.
Accordingly, embodiments of the present invention can provide
receptacle connectors and corresponding inserts of male plug
connectors having a smaller size in at least one of these
directions.
[0041] FIG. 3A illustrates a perspective view of a receptacle
connector 350 that can carry multiple high-speed data signals
according to embodiments of the present invention. This figure, as
with the other included figures, is shown for illustrative purposes
only and does not limit either the possible embodiments of the
present invention or the claims.
[0042] Receptacle connector 350 includes a shell 355 that surrounds
a tongue 360. Tongue 360 can be a type of insulator core, where a
cavity (space) surrounds the insulator core between the insulator
core and the shell, thereby forming a tongue. Tongue 360 has a
plurality of contact locations 330, where contacts 340 may be
located. In some embodiments, each contact location 330 has a
contact at that location. In other embodiments, some contact
locations may be empty, i.e. no contact may be at a particular
location.
[0043] A receptacle connector may also be referred to as a female
connector. A male plug connector may also be referred to as a male
connector or a plug connector. A connector insert of a male plug
connector may be inserted into the receptacle connector to form
connections in locations where contacts are located. In various
embodiments, these connections may be electrical, optical, or other
types of connections.
[0044] It may undesirable to carry a device having a connector
insert. For example, because of its protruding nature, the
connector insert may get bent or snagged. Accordingly, in systems
where a device is a portable electronic device such as a portable
media player, the receptacle connector can be located on the
portable electronic device, while the connector insert can be
located on a second device, such as a docking station or a cable
adapter. A docking station may also include a receptacle connector.
For example, a docking station may have a connector insert for
connecting to a portable electronic device, such as a portable
media player, and a receptacle connector for connecting to a cable
or other device.
[0045] Contacts 340 can carry a variety of signals, e.g., ground,
power, and multiple types of data signals. These data signals may
be high-speed data signals, and each interface for a particular
type of data signal may use multiple contacts. Examples of
high-speed data interfaces include USB 3.0 and DisplayPort, each of
which have a standard (requirements) for the signal behavior.
[0046] FIG. 3B is a block diagram illustrating the transmission of
DisplayPort and USB 3.0 signals between receptacle connector 350
and a male plug connector 300. However, these and other new
standards are often tough to satisfy. Problems with cross-talk and
signal integrity often arise. These problems can arise when a
standard is implemented using a connector specialized for that
particular standard, and are further complicated when signal lines
from various standards are combined into one connector, such as in
connectors 300 and 350.
[0047] In some embodiments, connectors 300 and 350 can provide
support for USB 3.0 (USB3) and legacy USB 2.0 (USB2). In one
embodiment, the connectors include two USB2 contacts, four USB3
contacts, and a USB power and a ground contact. The USB3 standard
is specified to transfer data at a "Super Speed" of 4.8 Gbps. An
impedance of 90 ohms plus and minus ten percent needs to be
maintained at this frequency to meet the USB3 specification.
[0048] In other embodiments, connectors 300 and 350 can provide
support for multiple lanes of DisplayPort communication. In one
example, the DisplayPort interface can provide a communication
channel for a DisplayPort sink device and a DisplayPort source
device over a main link, auxiliary lane link, and hot plug detect.
In one embodiment, the DisplayPort source device can have
receptacle connector 350 into which a male plug connector 300 may
be inserted to provide signals to the DisplayPort sink device
either directly or through a cable. Typically, a DisplayPort sink
device can be a monitor. The DisplayPort source device can be a
media player or other electronic device that includes a graphics
video source, such as a laptop or desktop computer.
[0049] The main link may include one, two, or four lanes of data
provided by the DisplayPort source device to the DisplayPort sink
device. Depending on whether one, two, or four lanes are supported,
this interface may require different numbers of contacts and may
support different monitor resolutions. For example, a single lane
can support resolutions of 1440.times.900, and require five
contacts. If two lanes are selected, the number of contacts
increases to seven, and the supported resolution can increase to
1680.times.1050. If four lanes are selected, eleven contacts are
required, while a resolution of 2560.times.1600 can be
supported.
[0050] The DisplayPort standard is specified to transfer data at a
rate of 1.3 MP when one lane is selected, 1.8 MP when two lanes are
selected, and 4.1 MP when four lanes are selected. Also, an
impedance of 100 ohms plus or minus ten percent needs to be
maintained at these data rates to meet the DisplayPort
specification. Thus, the USB3 specification and the DisplayPort
specification both require a specific impedance, plus or minus a
certain percentage. A designation of which signals can be used with
which contacts while providing these specifications is described
below.
[0051] FIG. 4 shows a contact (pin) designation chart 400
illustrating types of signals designated to be carried by contacts
of various contact locations according to embodiments of the
present invention. The contact locations may correspond to the
contact locations 330, which can be in a single row. The contact
location 1 may correspond to a contact location at either lateral
end of connector. The contact locations then increase sequentially
in number along the row.
[0052] In the example shown, the sequential contact locations are
labeled as starting from 1 to 12. In other embodiments, the number
of contacts may be greater than or less than 12, e.g., 11, 18, and
30. Additionally, the configuration for the designations shown may
occur at different contact locations, but with the same order. For
example, the contact location numbers shown could be from 7-18,
instead of from 1-12.
[0053] As depicted, the contact designations for data/power signals
410 are located in pairs with ground designations 420 separating
the pairs of signals 410. Thus, a ground designation 420 may occur
at every third location number. In one embodiment, an analog return
430 may be located at one end of a data signal pair (e.g. location
1) or separating different signal pairs (e.g. at location 7).
[0054] In one aspect, an analog return is a return associated with
an analog voltage signal. For example, the analog voltage signal
may be a power signal, where the analog return can act as a
negative terminal of a battery. In various embodiments, there may
be multiple powers provided on the connector, such as powers for
specific data interface (e.g. USB,
[0055] DisplayPort). As another example, the analog return also may
be associated with an analog audio or video signal.
[0056] The signals 410 may be a digital data signal, an analog data
signal, or a power signal. In one embodiment, the data signals can
be sent across a cable as a twisted signal pairs. For example,
certain DisplayPort signals may be sent as a differential pair
whose signals may be carried by contacts at locations that are next
to each other.
[0057] When contacts are placed into the contact locations and
signals are transmitted, the positioning of the ground between
pairs of data signals can help to provide high-speed data
communication. For example, this grounding configuration can
control impedance and reduce crosstalk by reducing the
electromagnetic coupling between the signal lines. Simulations of a
performance of a contact designation using such a grounding
configuration is now described.
[0058] FIGS. 5A-5C show plots illustrating simulated performance
characteristics of a connector having a contact designation
according to embodiments of the present invention. An S-Parameter
model was created using a contact configuration of 10 contacts with
four ground contacts, where two data contacts are between each
ground. The data signals in order are a DisplayPort lane pair, a
DisplayPort auxiliary pair, and a USB 3.0 pair.
[0059] The S-Parameter model was evaluated for impedance and Far
End Crosstalk (FEXT) up to 10 GHz. The simulation results showed
that this contact configuration meets USB impedance requirement
(90.OMEGA..+-.10%), the DisplayPort impedance requirement
(100.OMEGA..+-.10%), and had a crosstalk of less than 3%. The
insulator was modeled to be 15% glass fiber (GF) Liquid-crystal
polymer (LCP), with a dielectric constant of 2.5. The contacts were
modeled as C7025 (Cu--Ni--Si) having electrical conductivity of 40%
IACS (International Annealed Copper Standard), a thermal
conductivity of 98 Btu/sq ft/ft/hr/.degree. F.; Electrical
Resistivity, and 26.OMEGA. (cir mil/ft).
[0060] FIG. 5A shows a plot 500 illustrating a cross talk 510 for a
contact configuration of 6 consecutive data signals and a cross
talk 520 of 3 pairs of data signals with ground between the pairs
as shown in FIG. 4. The Y-axis shows the percentage level of cross
talk. The X-axis is time. As shown, cross talk 520 satisfies the
USB 3.0 requirement of being less than 3%, whereas the cross talk
510 is greater than 3%. A signal rise time of 80 pico seconds from
10% to 90% of the signal amplitude was used.
[0061] FIG. 5B shows a plot 550 illustrating a USB 3.0 differential
pair impedance 560 for a contact configuration having pairs of data
contacts separated by ground contacts. The Y-axis shows the
impedance of the USB contacts. The X-axis is time. As shown, the
impedance 560 satisfies the USB 3.0 requirement of being
90.OMEGA..+-.10%. To maintain signal integrity, the USB signal
pairs may also be separated from the USB power pins. A signal rise
time of 70 pico seconds from 10% to 90% of the signal amplitude was
used.
[0062] FIG. 5C shows a plot 570 illustrating a DisplayPort
differential impedance 580 for a contact configuration having pairs
of data contacts separated by ground contacts. The Y-axis shows the
impedance of the DisplayPort contacts. The X-axis is time. As
shown, the impedance 580 satisfies the DisplayPort requirement of
being 100.OMEGA..+-.10%. A signal rise time of 130 pico seconds
from 20% to 80% of the signal amplitude was used.
[0063] Various pinouts (e.g. which signals are designated for which
signal contacts) may be utilized by connectors according to
embodiments of the present invention. These pinouts may depend in
part on the standards that are supported by the connectors and
receptacles. Also, the pinouts may depend on which options of the
various standards are supported. For example, the number of pins
used by a DisplayPort interface may vary depending on the data
transfer rate that is supported. In some embodiments, these pinouts
conform to the configuration of pin designation chart 400, e.g.,
having pairs of signal contacts separated by a ground contact. Two
examples of signals that may be employed by receptacles and inserts
according to embodiments of the present invention are shown in the
following figure; other pinouts may be employed consistent with
embodiments of the present invention.
[0064] FIG. 6 shows an example of the types and specific number of
signals that may be carried on connectors according to embodiments
of the present invention. Pinouts 610 and 640 show types of signals
along with the number of contacts used for each type of signal.
Pinout 610 uses 30 contacts, and pinout 640 uses 29 contacts.
[0065] Pinout 610 includes contacts for the USB3 standard. The
contacts for USB3 include contacts for legacy support of USB2,
including USB power 612 and ground 614, as well as data contacts
616. Two pairs of data contacts 618 for USB3 support are also
included. Contacts 620 for a single lane DisplayPort interface are
also included.
[0066] Ground contacts may be used to provide isolation between
pairs signals, e.g., between pairs of DisplayPort contacts and
pairs of USB contacts. Accordingly, nine ground contacts 622 and a
power return 614 (which may also be considered a ground contact)
can be included to provide isolation. In one embodiment with
sequentially numbered contact locations for the contacts being in a
single row, a ground contact can be at a contact location 1, and
the other 9 ground contacts can be at every third contact location
(i.e. 4, 7, . . . ).
[0067] Other contacts including accessory identification and detect
624, accessory power 626, serial interface pins 628, analog audio
output 630, and composite analog video output 632 can also be
included.
[0068] Pinout 640 supports a higher speed DisplayPort interface
than pinout 610. Specifically, a second lane is added to the
DisplayPort 642, while the legacy audio and composite video outputs
are dropped. If 30 contacts exist in the connectors, the unused
contact for pinout 640 may be placed at any of the contact
locations.
[0069] FIGS. 6B-6F show examples of contact designations (pinouts)
for receptacle connectors and corresponding male plug connectors
according to embodiments of the present invention. In each pinout,
the "Pin" column provides a sequentially numbered list of contact
locations from one end of a connector to another end. In one
embodiment, these contact locations can correspond to the contact
locations 330 of receptacle connector 300 or to other contact
locations described herein.
[0070] Each one of these contacts locations can be designated for a
contact that has a particular function(s), thus the contact
location is designated for that particular function(s). The
"Function" column provides a list of one or more functions for
which the contact location is designated. Note that the contact
locations for the shell are designated at the end of the "Pin"
column. These contact locations can refer to the contact of shells
of the male plug connector with the receptacle connector. For
example, a shell of the male plug connector can contact a top and
bottom of a shell of the receptacle connector. Thus, in one
embodiment, these contact locations may not occur in a single row
of the other contact locations.
[0071] FIG. 6B shows a pinout 650 that supports USB3 and a single
channel of DisplayPort according to embodiments of the present
invention. Contact locations for ground are located at every third
contact location starting at location 1. In various embodiments,
the ground function can be provided by digital ground, a return for
audio signals (#28), a return for power (#22), and a remote sense
(#25), which can return a low side of load voltage. A ground may be
controlled from within the device (e.g. a media player) to which
the receptacle connector is part of or controlled by the device
that the male plug controller is part of. In one embodiment,
contact location 19 for ground is controlled by a media player in
which a receptacle connector is part of and may be used by an
accessory to determine when a media player is present.
[0072] Contact locations 2 and 3 are designated for a differential
pair of USB3 signals for transmitting, where for the corresponding
connector it would be for receiving. Contact locations 5 and 6 are
designated for a differential pair of USB3 signals for receiving.
Contact locations 8 and 9 are for USB2 signals. In an embodiment
where there are contacts at each of these locations, having each
differential pair separated by a ground helps to provide lower
cross talk and greater impedance control.
[0073] Contact locations 11 and 12 can be for one lane of
DisplayPort signals, and contact locations 14 and 15 can be for
DisplayPort auxiliary signals. In one aspect, locating the USB and
DisplayPort signal at one end of the sequential list provides
separation from analog signals at the other end.
[0074] Contact location 17 provides the hot plug detection for
DisplayPort, which may be used as an interrupt request, e.g., for a
source device to detect when a sink device (display) is attached.
The USB power can be located at contact location 18. In one
embodiment, the signal of the hot plug detect is not presented
often or only during an initial connection or reset, and thus may
not interfere much with the other DisplayPort signals.
[0075] An accessory identification signal (which can be used to
notify a media player of specific accessory device) and an
accessory power signal (which can be provided from a media player
to an accessory) can be located at contact locations 20 and 21,
respectively. Both of these signals can be a constant voltage, and
thus provide lower interference with each other. In one embodiment,
as the hot plug detect, USB voltage, accessory identification, and
accessory voltage can generally have a substantially constant
voltage, these designations can provide a buffer between the
digital signals and the analog signals, which do change frequently,
such as serial, analog audio, and analog video.
[0076] Contact locations 23 and 24 can be used for serial protocol.
Contact location 26 can be used to detect when an accessory is
connected. For example, an accessory can keep this signal low (e.g.
at or near ground); and when it is connected, the media player can
detect the low voltage. As the accessory detect can be connected to
a ground, it can provide low interference with the composite video
at location 27. Audio output can then be provided at locations 29
and 30.
[0077] FIG. 6C shows a pinout 660 that supports USB3 and a dual
channel of DisplayPort according to embodiments of the present
invention. In pinout 660, an accessory detect and the DisplayPort
hot plug detect are placed next to each other at locations 20 and
21, respectively. In one embodiment, these detect signals may not
change voltage often, and thus along with the accessory
identification signal and accessory power signal, can provide
shielding between the digital USB and DisplayPort signals and the
analog serial signals at locations 26 and 27. USB power can be
placed at location 29 next to power return at location 28. In this
example, contact location 30 does not have a designated function
and in some embodiments may not have a contact at this location.
Such a pinout may be used for a media player that is focused on
video. Audio for the video can be carried together with video in
either or both of the DisplayPort lanes. Again, all of the digital
signals can be placed toward one end of the connector, with the
analog signals being placed toward the other end.
[0078] FIG. 6D shows a pinout 670 that supports USB3 and a quad
channel of DisplayPort according to embodiments of the present
invention. Contacts 8 and 9 can be dual use between USB2 signals
and the DisplayPort auxiliary signals. In one aspect, the signals
can be controlled such that both types of signals may not be
transmitted at the same time. Internal circuitry of the devices can
be made to switch between the two types of signals. For example,
the hot plug detect signal may be used to communicate that the
DisplayPort auxiliary signals are to be used. The accessory detect
(#26) and DisplayPort hot plug detect (#27) can also be placed at
locations 23 and 24, similar to pinout 660. Contact locations 29
and 30 can have USB power and an accessory identification signal,
which may provide a lower level of interference with each other
since both can generally be a substantially constant voltage.
[0079] FIG. 6E shows a pinout 680 that supports USB2, audio, and
DisplayPort according to embodiments of the present invention.
Pinout 680 can support up to 18 contacts for contact locations in a
single row. Location 6 can be designated for a USB On-The-Go (OTG)
signal. In another embodiment, the hot plug signal is designated
for location 16, with the DisplayPort auxiliary signals be paled at
locations 17 and 18.
[0080] FIG. 6F shows a pinout 690 that supports USB2, audio, and
video according to embodiments of the present invention. Pinout 680
can support up to 18 contacts for contact locations in a single
row. An audio/video return can be designated for contact location
10 to suppress crosstalk and to provide optimal analog audio (#8
and 9)and analog video (#11).
[0081] FIG. 6G illustrates a mating sequence and wiping distance of
pinouts according to embodiments of the present invention. The
mating sequence provides for an initial mating between the shells.
The ground contacts are mated second. The signal contacts are mated
last. In one embodiment, the ground contacts can be staggered and
thus have a larger amount of wipe, than other contacts. These
features are discussed in greater detail with respect to FIGS. 11
and 14.
[0082] Some embodiments also provide connectors with a reduced
dimension of width, e.g., by reducing a spacing between contacts.
However, providing reduced size receptacle connectors and male plug
connectors that can support communications using one or more of the
newer high-speed communication interfaces (such as USB3 and
DisplayPort) can be difficult. To support these interfaces,
cross-talk should be minimized and signal integrity maintained.
Also, as described above, these specifications typically have
strict impedance matching requirements that need to be met to
reduce signal ringing and reflections. Accordingly, some
embodiments of the present invention can employ techniques such as
providing proper contact sizes, shapes, and spacing, as well as
other techniques.
[0083] FIG. 7 shows a top view of a conventional contact 700 used
in a receptacle connector. Contact 700 is a press fit style contact
that is inserted into a plastic housing and requires barbs for
contact retention. Other contacts would be located to the sides of
contact 700, i.e. above or below contact 700 as shown on the
paper.
[0084] Contact 700 is inserted into a plastic housing in a
direction 730. For example, the plastic housing may have slots into
which contact 700 is inserted, where the slots are smaller than
contact 700. Angled lead-ins 710 allows contact 700 to be inserted
easily into the plastic housing. Upon insertion, contact 700 digs
into the plastic housing in order to form a fixed seat in which
contact 700 will rest. For example, barb portions 720 of contact
700 are wider than the slot in the plastic housing so that plastic
material is still displaced, thereby providing the retention. Note
that barbs 720 and angled lead-in 710 are in the same plane as the
other contacts
[0085] Once contact 700 is seated into the housing and the
receptacle connector is finished, the receptacle connector may be
mated with a male plug connector. During the process of mating,
contact 700 encounters a corresponding contact from the male plug
connector along direction 740. When the mating occurs, a force is
imparted on contact 700 in direction 740. To prevent contact 700
from becoming unseated or otherwise dislodged during mating, the
series of barbs 720 of increasing width dig into the plastic
housing, thus providing a retention force.
[0086] However, contacts such as contact 700 may not be able to
support high-speed data communications, especially if a reduced
spacing between contacts is used. For example, the shape of contact
700 can cause problems in signal integrity. Since barbs 720 stick
out from a surface 750, the minimum distance between neighboring
contacts is reduced at barbs 720. Thus, the wide barb sections of
contact 700 reduce the contact spacing, which increases capacitive
coupling between adjacent contacts and affects connector
impedance.
[0087] Also, barbs 720 contain abrupt changes from surface 750. The
abruptness of this changing spacing between adjacent contacts also
alters the capacitive and inductive coupling along the electrical
path. In high-speed signals, this will affect circuit impedance
resulting in poor signal integrity.
[0088] FIG. 8A shows a top view of a contact 800 that can be used
in a reduced-width connector while maintaining signal quality at
high frequencies according to embodiments of the present invention.
Embodiments below generally describe such contacts with respect to
a receptacle connector. However, contact 800 may be used in a
receptacle connector or a male plug connector.
[0089] In one embodiment, contact 800 has a housing molded around
it (e.g. via insert molding), thereby allowing a certain shape.
During the molding process, insert molded contacts can be
encapsulated (partially or completely) in the insulator core. Such
a molding process can eliminate the need for barbs to facilitate
contact insertion and retention.
[0090] As shown, contact 800 can have side surfaces 850, which do
not have any protrusions, as does contact 700. Side surfaces 850
face the other contacts in the insulator core. In one embodiment,
side surfaces 850 are substantially parallel to each other except
for one or more recesses 810.
[0091] During a molding process, plastic (or other suitable
material) can flow into recesses 810. Since plastic is within
recess 810, contact 800 can be held into place during mating. Thus,
a retention force can be provided via recesses 810, and an axial
movement of contact 800 along direction 840 as a result of mating
can be reduced.
[0092] Since the holding mechanism is a recess and not a
protrusion, the minimum distance (and maximum distance) is defined
by the side surface 850 and not by a protrusion (such as barbs
720). Therefore, the spacing between the surfaces can be reduced,
which can provide a reduced width of the connector.
[0093] Additionally, recesses 810 of contact 800 provide more
subtle retention features, allowing for more uniform spacing
between adjacent contacts. In one embodiment, the surface of the
recess can be curved, and not have the sharp edges like contact
700. Such a curved surface for recesses 810 can result in stable
capacitive and inductive coupling along the electrical path, as
well as a consistent and matched circuit impedance and good signal
integrity. In another embodiment, a slope at any point on the
surface of a recess (or any point on the side surfaces 850) is at
an angle of less than 45 degrees with respect to the plane of the
side surface that the recess is on. Having such gradual slopes can
also result in stable capacitive and inductive coupling since the
change in the spacing between side surfaces of neighboring contacts
is small. Such gradual slopes can be on a recess that is curved or
one that is a combination of flat surfaces, each which has a slope
of less than 45 degrees.
[0094] The reduced width may be described as having reduced pitch
(average spacing between the contacts). In one embodiment, the
contacts have a pitch of less than 0.4 mm. In some embodiments, the
spacing may vary between contacts designated for different signals.
Thus, different sets of contacts may have a different spacing
between them. In one embodiment, a first set of contacts (e.g. at a
first region of contact locations) have approximately the same size
and spacing as a second set of contacts (e.g. at a second region of
contact locations). In another embodiment, the first set of
contacts have a different pitch as the second set of contacts.
[0095] Accordingly, embodiments of the present invention can
provide receptacle connectors and male plug connectors having a
reduced contact width and/or spacing that support high-speed data
interfaces. In one embodiment, the contact width and spacings are
configured to provide an impedance between 90 and 100 ohms such
that the impedance requirements for both USB3 and DisplayPort
standards are met. In another embodiment, the width and spacings
for the USB3 contacts are different than the width and spacing used
for the DisplayPort contacts, such that contact width and spacings
for each specification are optimized.
[0096] Some embodiments can also provide contacts with reduced
damage from mating. Typically, a contact on at least one of the
receptacle connector or the male plug connector has an exposed
front end, where mating occurs. This exposed front end has a
potential for stubbing (i.e. the contact ends butt up to one
another preventing proper engagement). If stubbing occurs, contacts
can be damaged, or in extreme cases, unseated from the housing.
[0097] FIG. 8B shows a side view of contact 880 (which may be
contact 800) that can provide reduced wear as a result from mating
according to embodiments of the present invention. A front end 820
of contact 800 has a shape that bends down from a top surface 860
of contact 880. Front end 820 of contact 880 can be embedded into
an insulator core to prevent stubbing against mating contact. As an
illustration of such embedding, a surface 870 of an insulator core
is shown as being above the front edge 823 of front end 820. In
this manner, the mating contact does not butt against the very
front edge 823, and a smooth path is provided for the mating
contact during the mating process.
[0098] In one embodiment, the insulator core may have a raised step
(not shown) between the contacts so that metal debris does not
cause a short. The insulator core thus may have slots in which the
contacts are embedded and have walls between the contacts, where
the walls are higher than surface 860 of contact 880. Thus, contact
880 may reside in a slot with part of the contact below the bottom
surface of the slot. A method making a connector, e.g., having a
contact 800 and/or contact 880, is now described.
[0099] FIG. 9 is a flowchart illustrating a method 900 for making
receptacle connector according to embodiments of the present
invention. In one aspect, method 900 may be used as a method of
manufacturing a plurality of receptacle connectors for a variety of
types of media players.
[0100] In step 910, a sheet of a conductive substance is stamped to
have a continuous solid strip with contact arms (e.g. with the
shape of contact 800 and/or 880) protruding like teeth from the
strip. In one embodiment, the stamped sheet has contacts to make a
plurality of connectors.
[0101] In step 920, the contact arms are plated. In one embodiment,
a front section of the contacts are plated with gold, and a back
section (near the strip) are plated with tin. In one embodiment,
the contacts may be made of copper covered with nickel, where the
nickel acts as a barrier layer between the copper and a layer of
gold. The gold may be used to resist corrosion and provide a good
electrical connection. The ends of the contacts may be plated with
tin to enhance solderability. Such a contact may provide, for
example, an electrical conductivity of approximately 40% IACS, a
thermal conductivity of approximately 98 BTU/sq ft/ft/hr/degrees F,
and an electrical resistivity of approximately 26 ohms (cir
mil/ft).
[0102] In step 930, an insulator core is insert molded onto the
contacts. For example, the contacts may be placed into a plastic
injection mold during the molding process. The molten plastic may
then flow around the contact completely or partially encapsulating
the contact. In one embodiment, the strip is fed with the contact
tips up during the molding process. The plastic may flow into a
recess (such as recess 810) in the contact, preventing any axial
movement during mating, as described above.
[0103] In one embodiment, the insulating material in the insulating
core may be a liquid crystal polymer, such as a 15% glass-filled
liquid crystal polymer, nylon, glass filled nylon, or other
appropriate material. The dielectric constant of such as material
may be, for example, 2.5. This insulating material may also be used
in male plug connectors described herein. The materials used in
either or both the receptacle connector common insulating core and
shell may be made of plastic or other nonconductive materials to
avoid interference with radio transmissions to or from an
electronic device.
[0104] In step 940, the contacts are bent down (e.g. by 80 degrees)
at a first point between the insulator core and the strip, and then
bent parallel at a second point between the first point and the
insulator core. In one embodiment, the contacts may be bent by
moving the insulator core while holding the strip. In some
embodiments, this core/contact assembly (or substantially identical
insulating core/contact assemblies, e.g., with varying numbers of
contacts) may be used in multiple types of electronic devices. For
example, the core/contact assembly may be used in all of the
devices of an entire line of media players.
[0105] In step 950, a shell is selected from a plurality of types
of shells and is attached to the insulator core. Each shell can be
configured to attach to the insulating core, and other insulating
cores made from steps 910-940. Each type of shell can be configured
to be used for a different electronic device. In one embodiment,
the shell is a metal shield. In another embodiment, the shell is
plastic, nylon, or other appropriate material. Thus, the insulator
substrate and shell may be nonconductive. The plastic shell can
have a metal ride plate for a latch of the make plug connector. The
metal plate may be added in a separate step.
[0106] In one embodiment, attaching the selected shell to the
respective insulating core includes placing the insulating core on
an inside bottom surface of the selected shell. Thus, the shell may
have a bottom configured to be adjacent to an insulating core. Such
a connector may have a reduced height, which is described in more
detail below.
[0107] The insulator core can have a stop at one surface (e.g. top
or bottom) that rests against the shell. Clips on the metal plate
can then attach into the core and prevent insert molded core from
being pushed out of the back of the shell.
[0108] In step 960, the contacts are cut from the strip.
Accordingly, embodiments of the present invention can utilize the
common portion of the insulating core/contact assembly among
receptacle connectors for different types of media players. An
example is shown in the following figure.
[0109] Some embodiments can also provide connectors with a reduced
dimension of height. A reduced height of a connector can provide a
slimmer electronic device that uses the connector. The reduced
height can be provided by placing an insulator core with contacts
on a surface of a surrounding shell. Thus, the connector may no
longer have a tongue.
[0110] FIG. 10 illustrates perspective and front views of a
receptacle connector 1000 that has a reduced height according to
embodiments of the present invention. Receptacle connector 1000
includes a shell 1010, an insulator core 1020, a plurality of
contact locations 1030 spaced apart in a single row on insulator
core 1020, and a plurality of contacts 1040 at contact location
1030.
[0111] In this example, the reduction in height is achieved by
eliminating a space between insulator core 1020 and a bottom of
shell 1010. In other words, the tab or tongue that is often
included in connectors is not present here. Specifically, insulator
core 1020 is adjacent to a bottom of the shell 1010. A cavity 1050
has a first region between insulator core 1020 and the sides of
shell 1010 and has a second region between insulator core 1020 and
the top of shell 1010. These regions can receive a corresponding
male plug connector.
[0112] In various embodiments, insulator core 1020 may be affixed
to the bottom of shell 1010 or may simply rest on the bottom of
shell 1010. In one embodiment, another material (e.g. a separate
insulator) may reside between the bottom of the shell and the
insulator core 1020, which can effectively make this another
material a part of shell 1010 or insulator core 1020. For example,
the insulator core may include an insulating substrate in which
contacts are attached, and this insulator core may be attached on
top of another material to form the insulator core. By eliminating
space between insulator core 1020 and the bottom of shell 1010, the
height of receptacle connector 1000 is reduced.
[0113] In one embodiment, insulator core 1020 includes a chamfer
1029 at a first end of a front surface of insulator core 1020. In
one aspect, chamfer 1029 is a sloped surface (e.g. at a 45 degree
angle) that can guide the male plug connector into lateral
alignment around insulator core 1020. Another chamfer can be
located at the opposite end of the front surface of insulator core
1020. This alignment is discussed more below.
[0114] In some embodiments, the width of receptacle connector 1000
is also reduced. This can be achieved by reducing the spacing
between contacts 1040. Thus, the contacts can be placed closer
together, thereby reducing the width of receptacle connector 1000.
In one embodiment, contact 800 of FIG. 8A can be used as contacts
1040, which can allow for support of high-speed data interfaces.
The width of a contact can also be reduced. In various embodiments,
the width, spacing, or both width and spacing of contacts 1040 are
reduced.
[0115] In this example, a contact 1040 is shown at each contact
location 1030. In various embodiments, one or more of these
contacts may be absent. For example, receptacle connector 1000 may
be located in a device having reduced functionality. In such a
situation, some contacts may not be needed, and may be omitted
consistent.
[0116] Also in this example, receptacle connector 1000 has an
opening that is somewhat rectangular. In other embodiments, the
opening can be rounded on the ends. In still other embodiments, the
opening may have other shapes, e.g., to receive different shapes of
male plug connectors. A male plug connector with a reduced height
is now described.
[0117] FIG. 11 illustrates a male plug connector 1100 with a
reduced height according to embodiments of the present invention.
In one aspect, a shell may not cover contacts of male plug
connector 1100, thereby providing a slimmer connector.
[0118] Male plug connector 1100 can include a housing 1120 that is
designed to accommodate a plurality of contacts spaced apart in a
single row. The contacts may be staggered within this single row. A
front end 1122 can be inserted into a receptacle connector (e.g.
connector 1000). As front end 1122 is inserted into the receptacle
connector, front end 1122 may be referred to as an insert.
[0119] A central bottom surface 1124 of front end 1122 includes a
plurality of contact locations 1130, at which a plurality of
contacts 1140 may reside. The bottom surface 1124 is central in
that is resides between two lateral bottom surfaces 1126. Front end
1122 also has a top surface (which would be on the bottom of the
figure as drawn). The use of bottom and top surfaces are used with
reference to a receptacle connector whose insulator core is
adjacent to a bottom surface of a shell (e.g. in embodiments shown
in FIG. 10). Accordingly, the male plug connector would be inserted
with the contacts pointing down, and thus for illustrative
purposes, the surfaces 1124 and 1126 are described as being bottom
surfaces.
[0120] Lateral bottom surfaces 1126 can be raised relative to
central bottom surface 1124. A chamfer 1129 on a front of the inner
wall between surfaces 1124 and raised surface 1126 may be used to
provide alignment with an insulator core during mating. In one
embodiment, chamfer 1129 has a 45 degree angle with respect to the
side wall extending from central bottom surface 1124 to a lateral
bottom surface. This alignment feature is discussed in more detail
below. In another embodiment, the central bottom surface extends to
a lateral edge of front end 1122, and this lateral bottom surfaces
are not present.
[0121] In some embodiments, a shell 1110 can cover the top surface
of front end 1122 and can cover lateral bottom surfaces 1126.
However, in one embodiment, shell 1110 does not cover central
bottom surface 1124. In another embodiment, shell 1110 does not
cover the two lateral bottom surface 1126, or covers only a
portion. The section of shell 1110 covering the top surface of the
front end of the housing can have holes that engage tabs of the
receptacle connector when the front end of the male plug connector
is inserted into the receptacle connector.
[0122] In one embodiment, a step 1128 extends from central bottom
surface 1124. As shown, step 1128 is located behind central bottom
surface 1124 towards a back end of housing 1120. Housing 1120 may
proceed further into the back of the connector 1100 into a base
section 1150. Step 1128 may extend past a cavity of the receptacle
connector when front end 1122 of male plug connector 1100 is
inserted into the receptacle connector. For example, step 1128 may
come in contact with an insulator core (e.g. 1020) when front end
1122 is fully inserted. Thus, step 1128 may mark a back edge of
front end 1122.
[0123] In some embodiments (and as shown), contact locations 1130
are staggered with a first portion located at a first distance from
a front edge 1123 of front end 1122 of housing 1120 and a second
portion of the contact locations located at a second distance from
front edge 1123. As shown, the second distance is larger than the
first distance. In some embodiments, contact locations 1130 include
holes in central bottom surface 1124 of housing 1120. Each hole may
be configured to receive a section of a contact, which is exposed
through the hole
[0124] Ground contacts 1140a may be placed at the first portion of
contact locations that are closer to front edge 1123 relative to
signal and power contacts 1140b. In various embodiments of the
present invention, other pins may be moved closer as well. For
example, the DisplayPort hot connect detect pin may be moved closer
to the front of the insert as well. Accordingly, male plug
connector 1100 can ensure that ground connections are made before
signal and power connections, thereby electrically protecting the
electronic device and a device connected to the electronic device.
Since contacts on the male plug connector 1000 are staggered,
contacts on a corresponding receptacle connector can be of a same
length. Thus, the corresponding receptacle connector can be of a
reduced depth.
[0125] In an embodiment that uses the contact designation 400 of
FIG. 4, the first portion of the contact locations can be separated
from each other by two contact locations of the second portion.
Thus, if ground contacts 1140a are placed at the first portion of
contact locations and signal contacts 1140b (which may include
power signals) are placed at the second portion of contact
locations, each ground contact may be separated from another ground
contact by two signal contacts. In one embodiment, the number of
ground contacts is nine. In another embodiment, the signal contacts
include a first set of signal contacts for carrying USB 3.0 signals
and a second set of signal contacts for carrying DisplayPort
signals.
[0126] In FIG. 11, a contact 1140 is shown at each contact location
1130. However, in various embodiments, one or more of these
contacts may be absent. For example, male plug connector 1100 may
reduced functionality relative to a total functionality that may be
provided to a receptacle connector. For example, only power and
ground contacts may be used when male plug connector is used as
part of a charger. As another example, only contacts for audio
signals and audio ground may be present. Accordingly, in some
situations, some contacts may not be needed, and may be omitted
consistent.
[0127] When a male plug connector is inserted into a receptacle
connector according to an embodiment of the present invention, it
is important that the connector insert can only be inserted into
the receptacle connector correctly. That is, it is important that
the male plug connector cannot be inserted into the receptacle
connector in an upside down manner. To prevent such an accidental
insertion, embodiments of the present invention employ keying using
the contact insulator core of a receptacle connector and insert of
the male plug connector. If a male plug connector is inserted
upside-down, a housing contacts an insulator core, which prevents
the insert from proceeding further. An example of this is shown in
the following figure.
[0128] FIG. 12 illustrates keying aspects of connectors to prevent
accidental inverted insertion of a male plug connector 1250 into a
receptacle connector 1200 according to embodiments of the present
invention. Receptacle connector 1200 can include an insulator core
1220 on which contact 12450 is located. Insulator core 1220 can be
adjacent to a bottom of a shell 1210. Male plug connector 1250 can
include a housing 1225 that contains a contact 1245. A plug shell
1215 can cover a top surface of housing 1225.
[0129] In this figure, an attempt is made to the insert male plug
connector 1250 upside-down into receptacle connector 1200. Upon
this incorrect insertion, plug shell 1215 makes contact with the
contact insulator core 1220, thus preventing continued insertion.
In one embodiment, contact 1240 is recessed from the front of the
contact insulator core 1220 to protect it during an improper
insertion attempt.
[0130] It is also important that a male plug connector fit
correctly with a limited amount of play in a receptacle connector.
If there is a misalignment or play in the fit, contacts may lose
contact or form undesirable connections. Accordingly, embodiments
of the present invention provide accurate alignment for the
connection of male plug connectors with receptacle connectors.
Alignment can be achieved on a macro and micro level.
[0131] FIG. 13 illustrates mechanisms for aligning a male plug
connector with a receptacle connector according to an embodiment of
the present invention. FIG. 13 shows the connectors mated. A front
view and a cross-sectional aerial view are shown.
[0132] In this example, macro-alignment can be provided by a
receptacle connector shell 1310 and a male plug connector shell
1320. An outer width of male plug connector shell 1320 is less than
an inner width of receptacle connector shell 1310, and a height of
male plug connector shell 1320 is less than a height of a cavity of
receptacle connector shell 1310. Thus, male plug connector shell
1320 can fit inside receptacle connector shell 1310. The widths can
be manufactured with a tolerance that provides a space of up to
0.10 mm between the sides of the shells. The heights can be
manufactured with a tolerance that provides a space of up to 0.05
mm between the shells on the top and bottom.
[0133] Micro-alignment can be provided by a receptacle connector
core 1340 and a plug housing 1330 having a recess. For example,
housing 1330 can have a recess with a width defined by raised
lateral surfaces at the ends of a central bottom surface containing
contacts, e.g., as described for FIG. 11. When inserted with a
proper orientation, a width of the receptacle core 1340 is smaller
than a width of the recess in plug housing 1330. Thus, receptacle
core 1340 can fit inside the recess in plug housing 1330.
[0134] In one embodiment, these widths for micro-alignment are
manufactured with a tolerance that provides a space of up to 0.04
mm between the sides of the shells. In one aspect, the insulator
materials of receptacle connector core 1340 and plug housing 1330
can be machined with higher tolerances than the materials of the
shells, and thus are used for the micro-alignment.
[0135] In one embodiment, receptacle connector core 1340 includes a
chamfer (e.g. 1029 of FIG. 10) at each end of a front surface, and
plug housing 1330 has a chamfer (e.g. 1129 of FIG. 11) at each
front edge of the side walls defining the recess. When the male
plug connector is inserted with a proper orientation into the
receptacle connector, the chamfers on one edge meet and cause plug
housing 1330 to slide into proper alignment. For example, the
chamfer of the receptacle connector can be sloped (e.g. at 45
degrees) to push a lateral bottom surface and/or edge of a plug
shell 1320 of the male plug connector outward to a side edge of
receptacle core 1340. The chamfer of the male plug connector can
push a side edge of receptacle core 1340 inward to a side wall
extending from a central bottom surface to a lateral bottom surface
of the male plug connector. In one embodiment, the angles of the
corresponding chamfers can be complementary in that they sum up to
90 degrees, but have different values (e.g. 40 degrees and 60
degrees).
[0136] FIGS. 14A-14C illustrate cross-sectional side views of
different stages during an insertion of a male plug connector 1450
into a receptacle connector 1400 according to embodiments of the
present invention. FIG. 14A shows male plug connector 1450 at a
beginning of insertion into receptacle connector 1400, and FIGS.
14B and 14C show male plug connector 1450 at later stages of
insertion. For these figures, forward describes the direction that
is depicted to the left on the paper.
[0137] In one embodiment, ground contacts of male plug connector
1450 can be located forward relative to other contacts in order to
engage corresponding contacts of the receptacle connector first
(e.g. as described for FIG. 11). As the ground contacts in male
plug connector 1450 can be moved forward, the contacts of
receptacle connector 1400 can be made a same length and shorter
than if the grounds contacts were longer. This configuration can
maintain ground as a make-first break-last connection, while also
reducing the depth of receptacle connector 1400.
[0138] FIG. 14A shows male plug connector 1450 at an initial point
of mating with receptacle connector 1400. Ground contact 1445a of
male plug connector 1450 has not reached ground contact 1440a of
receptacle connector 1400 yet. In one embodiment, ground contact
1445a can be a spring-loaded contact. For example, a middle section
of ground contact 1445a can protrude through a contact location
1435, which may be a hole. A front section of ground contact 1445a
can hook into a slot 1460 that anchors the front section. A back
section of ground contact 1445a can extend from contact location
1430 to a fixed location at an insulator core 1465. Ground contact
1445a is allowed to be pushed up like a spring as it may be fixed
only at the ends shown. Other contacts can be positioned in a
similar manner.
[0139] In one embodiment, male plug connector 1450 includes a
moveable door 1470, which may slide back or otherwise retract
during insertion. Moveable door 1470 can provide protection of
contacts of male plug connector 1450 when male plug connector 1450
is not inserted into receptacle connector 1400. Moveable door 1470
may cover a central bottom surface of housing 1425, where the
central bottom surface can be located between two raised lateral
surfaces as described above.
[0140] FIG. 14B shows ground contact 1445a of male plug connector
1450 at an initial contact point 1447a with ground contact 1440a of
receptacle connector 1400. Male plug connector 1450 has moved
further forward into receptacle connector 1400. As an example,
ground contact 1445a may have touched a top elbow of ground contact
1440a and slid up on top of contact 1445a. Moveable door 1470 is
shown as having slid further open as male plug connector 1450 has
moved into a position of further insertion.
[0141] A signal contact 1445b lies in a staggered contact location
that is further back than the contact location for ground contact
1445a. Thus, signal contact 1445b has not touched a contact of
receptacle connector yet. Accordingly, ground contact 1445a is able
to provide a make-first break-last connection.
[0142] FIG. 14C shows a signal contact 1445b of male plug connector
1450 at an initial contact point 1447b with ground contact 1440b of
receptacle connector 1400. Ground contact 1445a is shown in front
of signal contact 1445b. Ground contact 1445a is still contacting
ground contact 1440a, but at a point further toward the back of
receptacle connector 1400. Moveable door 1470 has slid further open
as male plug connector 1450 has moved even further into receptacle
connector 1400.
[0143] In one embodiment, besides allowing a reduced depth of
receptacle connector 1400, the placement and structure of the
contacts 1440 in receptacle connector 1450 can provide for better
signal quality. The front section of contact 1445 (i.e. forward
from contact point 1447) can act as an antenna, which can receive
noise, thereby causing poor signal or ground quality. In one
embodiment, the middle section of a contact 1445 can be provided
with a tight bend and the front section can be made short so as to
reduce the antenna behavior of the front section of contact 1145.
Additionally, the lengths of each contact 1445 forward from each
respective contact point 1447 can be made the same and to have a
same shape. Thus, even though the front sections may act as an
antenna and receive noise, the level of noise may be equal. With
equal levels of noise, the effect from the noise may cancel, and
good signal quality may be achieved.
[0144] The antenna behavior may also result from a length between
contact point 1447a to a front of contact 1440a, which may be
longer than the length between contact point 1447b to a front of
contact 1440b. However, such antenna behavior will be smaller than
that of a front section of contact 1445 as contacts 1440 are
embedded in an insulator, which will shield contacts 1440. Also, in
cases where receptacle connector 1400 is part of an electronic
device, the ends of contacts 1440 are farther away from internal
circuitry of the electronic device, which can be a source of
electrical noise. Accordingly, since such length is at a front of
the connector, it is not as susceptible to noise.
[0145] Additionally, in one embodiment, the length that a signal
travels along the contacts from the back of one connector to the
back of the other connector can be made the same for each set of
corresponding contacts. For example, although the contact point
1447a is further forward than contact point 1447b (making the
signal length on contacts 1447a smaller), contact 1445a may be made
longer than contact 1445b to account for the difference. Besides
being longer, contact 1445a can have a slightly different shape to
account for the fact that the signal is on the contact 1445a (which
is on an angle) for a longer distance than on contact 1445b. The
shape can also account for the extra distance that a signal spends
on contact 1440b than on contact 1440a.
[0146] FIG. 15 illustrates a male plug connector 1500 with a
reduced height and a moveable door 1570 according to embodiments of
the present invention. Male plug connector 1500 can have some of
the same or similar features as other male plug connectors
mentioned herein.
[0147] Male plug connector 1500 can include a housing that is
designed to accommodate a plurality of contacts spaced apart in a
single row. An insert 1522 can be inserted partially or completely
into a receptacle connector (e.g. connector 1000). A central bottom
surface 1524 of insert 1522 includes a plurality of contact
locations 1530, at which a plurality of contacts 1540 may reside.
Central bottom surface 1524 resides between two lateral bottom
surfaces 1526.
[0148] Moveable door 1570 can cover contacts 1540 when male plug
connector 1500 is not inserted into a corresponding receptacle
connector. In one embodiment, moveable door can slide back into
base 1550. For example, upon insertion, moveable door 1570 can come
in contact with an insulator core of the corresponding receptacle
connector. As insert 1522 moves forward, the insulator core can
push moveable door 1570 into base 1550, thereby exposing contacts
1540 so that they may come in contact with contacts of the
corresponding receptacle connector. In another embodiment, a user
can move the moveable door 1570 prior to insertion.
[0149] In one embodiment, lateral bottom surfaces 1526 can be
raised relative to central bottom surface 1524 and extend past a
wall 1528, thereby creating a groove that moveable door 1570 can be
guided by as it moves. Wall 1528 can have a chamfer located at the
front, which may be used to provide alignment with an insulator
core during mating. In some embodiments, a shell 1510 can cover a
top surface of insert 1522 and can cover lateral bottom surfaces
1526.
[0150] Embodiments described herein can provide male plug
connectors and female receptacle connectors that can be of a
reduced size and support high-speed communication standards, such
as USB 3.0 and DisplayPort. In some embodiments, a receptacle
connector has an insulator core adjacent to a surface of a shell to
reduce a height of the connector. In other embodiments, contacts of
a connector are provided with a shape that helps to provide a
retention force to hold the contact within an insulator while
providing good signal quality, even at a reduced contact pitch.
Other embodiments can provide alignment when mating the connectors,
reduced depth of the receptacle connector, and reductions in
noise.
[0151] The above description of exemplary embodiments of the
invention has been presented for the purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form described, and many modifications and
variations are possible in light of the teaching above. The
embodiments were chosen and described in order to best explain the
principles of the invention and its practical applications to
thereby enable others skilled in the art to best utilize the
invention in various embodiments and with various modifications as
are suited to the particular use contemplated.
* * * * *